EP3224395B1 - A method of producing a sandwich panel core of mineral wool fibres - Google Patents

A method of producing a sandwich panel core of mineral wool fibres Download PDF

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Publication number
EP3224395B1
EP3224395B1 EP15800789.8A EP15800789A EP3224395B1 EP 3224395 B1 EP3224395 B1 EP 3224395B1 EP 15800789 A EP15800789 A EP 15800789A EP 3224395 B1 EP3224395 B1 EP 3224395B1
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EP
European Patent Office
Prior art keywords
density
fibre
mineral
top layer
lamellae
Prior art date
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Application number
EP15800789.8A
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German (de)
French (fr)
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EP3224395A1 (en
Inventor
Christian Strüwing
Jens Eg RAHBEK
Mohammed Rashid
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rockwool AS
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Rockwool International AS
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Publication date
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Priority to PL15800789T priority Critical patent/PL3224395T3/en
Priority to SI201530609T priority patent/SI3224395T1/en
Publication of EP3224395A1 publication Critical patent/EP3224395A1/en
Application granted granted Critical
Publication of EP3224395B1 publication Critical patent/EP3224395B1/en
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D04H1/4226—Glass fibres characterised by the apparatus for manufacturing the glass fleece
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B32B2255/205—Metallic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/08—Animal fibres, e.g. hair, wool, silk
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/18—Longitudinally sectional layer of three or more sections
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24124—Fibers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/24992—Density or compression of components

Definitions

  • the present invention relates to a method of producing a sandwich panel of mineral wool fibres.
  • WO 92/10602 there is disclosed a method of producing sandwich panel core composed of interconnected mineral wool fibre lamellae, where the general fibre direction of in the lamellae is predominantly at right angles to the major surfaces of the resulting sandwich panel to increase compression strength.
  • WO 2005/124048 there is disclosed a reinforced sandwich panel core, where there are reinforcements in the core to increase compression strength.
  • a simple method for producing a panel with increased compression strength of the core i.e. the base layer.
  • the compression strength of the panel can be easily selected and produced without any significant extra production costs, since the thickness of the high density top layer may easily be adjusted when the mineral fibre wool product is produced, for instance in accordance with WO 2014/090670 .
  • the step of re-joining the lamellae after the rotation comprises the step of adhering the cut and rotated lamellae to each other by applying an adhesive.
  • the dual density mineral fibre product is preferably formed by the steps of:
  • the fibre orientation of the top layer is substantially horizontal before the step of cutting.
  • the fibre orientation of the base layer is substantially vertical before the step of cutting.
  • the top layer after compression is preferably provided with a first density of at least two to three times the second density of the base layer.
  • the first density is 150-300 kg/m 3 , preferably approx. 230-250 kg/m 3 .
  • the second density is 50-100 kg/m 3 , preferably approx. 65-70 kg/m 3 .
  • An advantageous aspect of the invention relates to a mineral wool fibre panel core, wherein the panel comprises first and second elongate elements which are parallel to each other, and wherein the first elongate elements have a first density and with a fibre orientation parallel to the top and bottom surfaces of the panel, and the second elongate elements have a second density and with a fibre orientation substantially orthogonal to the top and bottom surfaces.
  • the width of the first areas is 80-90 mm, preferably 85 mm and the width of the second areas is 15-20, preferably 17 mm.
  • Facings of different type and material may be may be applied to the mineral wool fibre sandwich panel, e.g. glass fibre reinforced facings or wood fibre reinforced facings. Such facings may be relatively rigid and strong, but preferably pliable enough to be supplied in rolls to facilitate mass production.
  • a sandwich panel comprising a sandwich panel core of the above-mentioned kind further comprises a metal facing on the top and bottom surfaces of the sandwich panel core.
  • a cured mineral fibre product 1 which preferably is made by the manufacturing method according to WO2014/090670 .
  • the mineral fibre product is a dual density panel comprising at a top layer 2 comprising mineral fibres with a first density and a base layer 3 comprising mineral fibres with a second density, which is considerably lower than said first density.
  • the top layer 2 and the base layer 3 have different fibre orientations.
  • the top layer 2 has the mineral fibres generally horizontally oriented whereas the base layer 3 has a vertical fibre orientation.
  • the vertical fibre orientation in the base layer 3 is preferably achieved by producing the mineral fibre web with horizontal fibre orientation and then cutting this web into lamellae and then assembling these lamellae into the base layer 3 of the product, such as described in WO2014/090670 .
  • the cured dual density mineral fibre product schematically shown in fig. 1 is then the starting panel for the method of producing a sandwich panel of mineral wool fibres according to a preferred embodiment of the invention.
  • the product 1 is cut into lamellae 1', 1", 1"', 1"" as shown in fig. 2 .
  • the cutting action is performed by suitable cutting tools 4, such as a band saw or the like.
  • An applicator 5 may also be arranged to apply an adhesive 5', such as glue, to for instance the top surface of the product 1.
  • the adhesive 5' could be applied either to the top or bottom surface or to both surfaces depending on the design of the application action.
  • the step of applying the adhesive 5' may preferably be carried out after the cutting of the product 1 into the lamellae1', 1", 1"', 1"".
  • the cutting and the application of the adhesive may be altered or the step of applying adhesive may be dispensed with as the lamellae may be permanently joined with the need for applying adhesive, which could lower the fire protecting properties of the finished product.
  • the lamellae 1', 1", 1"', 1"" are rotated 90 degrees by a suitable rotating action 6, as indicated in fig. 3 , so that the top layer 2 with high density is vertically oriented and then the lamellae 1', 1", 1"', 1"" are rejoined together.
  • the lamellae 1', 1", 1"', 1"" carry layer of adhesive 5' at least on the top of the top layer 2 so that the lamellae 1', 1", 1"', 1"" are adhered together to form a sandwich panel 7 as shown in fig. 4 with the high density layers being vertically arranged and the low density areas 3 therebetween.
  • the high density layers 2 will then form reinforcing stringers that ensure a good compression strength of the sandwich panel.
  • TS tensile strength
  • TSM compression
  • CSM compression
  • SS sheer strength
  • SSM sheer strength
  • Lambda the total density and thermal insulation value
  • the product Spanrock M was used as a reference.
  • This board is designed for accurate cutting of lamellae providing a core material for sandwich panels and other multi-layer systems.
  • the roof board referred to as the "old roof board” is made by a method as disclosed in WO2014/090670 , and the “new board” is made according to the present invention.
  • the dimensions for the new board are a top layer thickness of 17 mm, a top layer density of 230 kg/m 3 and a bottom layer of 85 mm thickness and 70 kg/m 3 in density.
  • the thickness of all the products in the comparative test is 102 mm.

Description

  • The present invention relates to a method of producing a sandwich panel of mineral wool fibres.
  • In WO 92/10602 there is disclosed a method of producing sandwich panel core composed of interconnected mineral wool fibre lamellae, where the general fibre direction of in the lamellae is predominantly at right angles to the major surfaces of the resulting sandwich panel to increase compression strength. In WO 2005/124048 there is disclosed a reinforced sandwich panel core, where there are reinforcements in the core to increase compression strength.
  • To improve the thermal insulation performance of such a panel it is desired to reduce the density. This is also advantageous from a cost perspective. However, when the density of the mineral wool core, i.e. the base layer, is reduced the compression strength is reduced too. Therefore, it is the object by the present invention to provide a method of producing mineral wool fibre panels with increased compression strength while the production of the panels remains cost-effective.
  • This object is achieved by a method of producing a sandwich panel core of mineral wool fibres from a cured mineral fibre product, said method comprising the steps of:
    • providing a cured mineral fibre product with a dual density comprising a top layer comprising mineral fibres with a first density and a base layer comprising mineral fibres with a second density, which is at least two times lower than said first density, and wherein said top layer and said base layer have different fibre orientations;
    • cutting said mineral fibre product into a plurality of lamellae,
    • rotating said lamellae 90 degrees, and
    • re-joining the lamellae so that the top layers with high density are vertically oriented.
  • By a method according to the invention, a simple method is provided for producing a panel with increased compression strength of the core, i.e. the base layer. By cutting the product into lamellae and then rotating the lamellae around their longitudinal axis by 90 degrees, the high density top layer of the dual density mineral fibre product will then form reinforcing stringers that ensure the necessary compression strength of the panel.
  • By the invention it is found advantageous that the compression strength of the panel can be easily selected and produced without any significant extra production costs, since the thickness of the high density top layer may easily be adjusted when the mineral fibre wool product is produced, for instance in accordance with WO 2014/090670 .
  • It is generally not considered necessary to join adjacent lamellae, but in some specific applications it may be considered advantageous, e.g. if the sandwich panel core may be subject to shear force. In such case the step of re-joining the lamellae after the rotation comprises the step of adhering the cut and rotated lamellae to each other by applying an adhesive.
  • The dual density mineral fibre product is preferably formed by the steps of:
    • providing the top layer web comprising uncured mineral wool;
    • providing the base layer web comprising cured mineral wool;
    • joining the uncured top layer web and the cured base layer web to form an assembled laminate; and then curing the top layer web in a curing oven by transporting the assembled laminate into a curing oven comprising an upper conveyor and a lower conveyor for curing the assembled laminate, said assembled laminate being positioned between said upper and lower conveyors, wherein the uncured top layer web is compressed by at least 50 % upon entry into the curing oven.
  • By this method of preparing the mineral fibre wool product, the fibre orientation of the top layer is substantially horizontal before the step of cutting. Similarly, the fibre orientation of the base layer is substantially vertical before the step of cutting. During this method of preparation, the top layer after compression is preferably provided with a first density of at least two to three times the second density of the base layer.
  • In an embodiment of the invention, the first density is 150-300 kg/m3, preferably approx. 230-250 kg/m3. Additionally, the second density is 50-100 kg/m3, preferably approx. 65-70 kg/m3.
  • An advantageous aspect of the invention relates to a mineral wool fibre panel core, wherein the panel comprises first and second elongate elements which are parallel to each other, and wherein the first elongate elements have a first density and with a fibre orientation parallel to the top and bottom surfaces of the panel, and the second elongate elements have a second density and with a fibre orientation substantially orthogonal to the top and bottom surfaces.
  • Preferably, the width of the first areas is 80-90 mm, preferably 85 mm and the width of the second areas is 15-20, preferably 17 mm.
    Facings of different type and material may be may be applied to the mineral wool fibre sandwich panel, e.g. glass fibre reinforced facings or wood fibre reinforced facings. Such facings may be relatively rigid and strong, but preferably pliable enough to be supplied in rolls to facilitate mass production.
  • In a preferred embodiment a sandwich panel comprising a sandwich panel core of the above-mentioned kind further comprises a metal facing on the top and bottom surfaces of the sandwich panel core.
  • In the following the invention is described in more detail with reference to the drawings, in which:
    • Fig. 1 is a schematic cross-sectional view of a mineral wool fibre panel according to the prior art;
    • Figs. 2 and 3 show the method steps according to the present invention; and
    • Fig. 4 shows the sandwich panel of mineral wool fibres according to the invention.
  • In fig. 1, there is shown a cured mineral fibre product 1 which preferably is made by the manufacturing method according to WO2014/090670 . The mineral fibre product is a dual density panel comprising at a top layer 2 comprising mineral fibres with a first density and a base layer 3 comprising mineral fibres with a second density, which is considerably lower than said first density. The top layer 2 and the base layer 3 have different fibre orientations. The top layer 2 has the mineral fibres generally horizontally oriented whereas the base layer 3 has a vertical fibre orientation. The vertical fibre orientation in the base layer 3 is preferably achieved by producing the mineral fibre web with horizontal fibre orientation and then cutting this web into lamellae and then assembling these lamellae into the base layer 3 of the product, such as described in WO2014/090670 .
  • The cured dual density mineral fibre product schematically shown in fig. 1 is then the starting panel for the method of producing a sandwich panel of mineral wool fibres according to a preferred embodiment of the invention.
  • According to this embodiment, the product 1 is cut into lamellae 1', 1", 1"', 1"" as shown in fig. 2. The cutting action is performed by suitable cutting tools 4, such as a band saw or the like. An applicator 5 may also be arranged to apply an adhesive 5', such as glue, to for instance the top surface of the product 1. The adhesive 5' could be applied either to the top or bottom surface or to both surfaces depending on the design of the application action. In order not to interfere with the cutting action, the step of applying the adhesive 5' may preferably be carried out after the cutting of the product 1 into the lamellae1', 1", 1"', 1"". However, by the invention it is realised that depending on the type of adhesive 5' the order of these two steps, the cutting and the application of the adhesive, may be altered or the step of applying adhesive may be dispensed with as the lamellae may be permanently joined with the need for applying adhesive, which could lower the fire protecting properties of the finished product.
  • After the cutting action, the lamellae 1', 1", 1"', 1"" are rotated 90 degrees by a suitable rotating action 6, as indicated in fig. 3, so that the top layer 2 with high density is vertically oriented and then the lamellae 1', 1", 1"', 1"" are rejoined together. The lamellae 1', 1", 1"', 1"" carry layer of adhesive 5' at least on the top of the top layer 2 so that the lamellae 1', 1", 1"', 1"" are adhered together to form a sandwich panel 7 as shown in fig. 4 with the high density layers being vertically arranged and the low density areas 3 therebetween.
  • The high density layers 2 will then form reinforcing stringers that ensure a good compression strength of the sandwich panel.
  • In a comparative test, three boards are tested for strength and modulus in three dimensions, i.e. tensile strength (TS) and modulus (TSM), compression (CS) and modulus (CSM), and sheer strength (SS) and modulus (SSM) as well as the total density and thermal insulation value, Lambda, was measured. The test results are listed in table 1.
  • The product Spanrock M was used as a reference. This board is designed for accurate cutting of lamellae providing a core material for sandwich panels and other multi-layer systems. The roof board referred to as the "old roof board" is made by a method as disclosed in WO2014/090670 , and the "new board" is made according to the present invention.
  • The dimensions for the new board are a top layer thickness of 17 mm, a top layer density of 230 kg/m3 and a bottom layer of 85 mm thickness and 70 kg/m3 in density. The thickness of all the products in the comparative test is 102 mm. Table 1
    Board type TS [kPa] TSM [kPa] CS [kPa] CSM [kPa] SS [kPa] SSM [kPa] Density [kg/m3] Lambda [mW/mK]
    Spanrock M 150 15000 70 4000 50 3500 100 42
    Old roof board 140 13000 60 6000 45 4000 96 37
    New board 150 20000 70 7500 50 4500 100 37
  • In general, when terms like "horizontal" and "vertical" or similar directional references are used in the present disclosure, these terms are meant to be understood as relative terms e.g. where the term "vertical" refers to the direction of the thickness of the web, panel or product and "horizontal" refers to a direction perpendicular to the thickness of the web, panel or product.
  • Above, the invention is described with reference to one preferred embodiment of the invention. However, it is realised that other variant may be provided without departing from the scope of the accompanying claims.

Claims (11)

  1. A method of producing a sandwich panel core of mineral wool fibres from a cured mineral fibre product, said method comprising the steps of:
    - providing a cured mineral fibre product with a dual density comprising a top layer comprising mineral fibres with a first density and a base layer comprising mineral fibres with a second density, which is at least two times lower than said first density, and wherein said top layer and said base layer have different fibre orientations;
    - cutting said mineral fibre product into a plurality of lamellae,
    - rotating said lamellae 90 degrees, and
    - re-joining the lamellae so that the top layers with high density are vertically oriented.
  2. A method according to claim 1, wherein the step of rejoining comprises adhering the cut and rotated lamellae to each other by applying an adhesive.
  3. A method according to claim 1 or 2, whereby said cured mineral fibre product is formed by the steps of:
    - providing the top layer web comprising uncured mineral wool;
    - providing the base layer web comprising cured mineral wool;
    - joining the uncured top layer web and the cured base layer web to form an assembled laminate;
    - curing the top layer web in a curing oven by transporting the assembled laminate into a curing oven comprising an upper conveyor and a lower conveyor for curing the assembled laminate, said assembled laminate being positioned between said upper and lower conveyors;
    wherein the uncured top layer web is compressed by at least 50 % upon entry into the curing oven.
  4. A method according to claim 3, wherein the fibre orientation of the top layer is substantially horizontal before the step of cutting.
  5. A method according to claim 3 or 4, wherein the fibre orientation of the base layer is substantially vertical before the step of cutting.
  6. A method according to any of the claims 3 to 5, wherein the top layer after compression is provided with a first density of two to three times the second density of the base layer.
  7. A method according to any of the preceding claims, wherein the first density is 150-300 kg/m3, preferably approx. 230-250 kg/m3.
  8. A method according to any of the preceding claims, wherein the second density is 50-100 kg/m3, preferably approx. 65-70 kg/m3.
  9. A mineral wool fibre panel core made by performing a method according to any of the preceding claims, wherein the panel comprises first and second elongate elements which are parallel to each other, and wherein the first elongate elements have a first density and with a fibre orientation parallel to the top and bottom surfaces of the panel, and the second elongate elements have a second density and with a fibre orientation substantially orthogonal to the top and bottom surfaces.
  10. A panel according to claim 9, wherein the width of the first areas is 80-90 mm, preferably 85 mm and the width of the second areas is 15-20, preferably 17 mm.
  11. Sandwich panel comprising a sandwich panel core according to claim 9 or 10, and further comprising a metal facing on the top and bottom surfaces of the sandwich panel core.
EP15800789.8A 2014-11-24 2015-11-24 A method of producing a sandwich panel core of mineral wool fibres Active EP3224395B1 (en)

Priority Applications (2)

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PL15800789T PL3224395T3 (en) 2014-11-24 2015-11-24 A method of producing a sandwich panel core of mineral wool fibres
SI201530609T SI3224395T1 (en) 2014-11-24 2015-11-24 A method of producing a sandwich panel core of mineral wool fibres

Applications Claiming Priority (2)

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EP14194479 2014-11-24
PCT/EP2015/077492 WO2016083368A1 (en) 2014-11-24 2015-11-24 A method of producing a sandwich panel core of mineral wool fibres

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EP (1) EP3224395B1 (en)
PL (1) PL3224395T3 (en)
RU (1) RU2694377C2 (en)
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3628481B1 (en) 2018-09-27 2021-11-03 Rockwool International A/S A sandwich panel
PL3653375T3 (en) * 2018-11-15 2022-01-03 Rockwool International A/S A method of producing an insulation board for a sandwich panel, an insulation board and a method for producing a sandwich panel

Family Cites Families (7)

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CA1209893A (en) * 1983-10-24 1986-08-19 Neil M. Cameron Reoriented glass fiber board product and method and apparatus for making same
DK165926B (en) * 1990-12-07 1993-02-08 Rockwool Int PROCEDURE FOR THE MANUFACTURE OF INSULATION PLATES COMPOSED BY INVOLVED CONNECTED STABLE MINERAL FIBER ELEMENTS
EP1456444B2 (en) 2001-12-21 2014-01-01 Rockwool International A/S Mineral fibre batts and their production
RU2280132C1 (en) * 2004-11-15 2006-07-20 Иван Николаевич Калинин Structural sandwich panel
EP1977054B1 (en) 2006-01-26 2020-03-11 Rockwool International A/S Sandwich element
FI122565B (en) * 2008-07-31 2012-03-30 Paroc Oy Ab Concrete bell elements and process for its preparation
CA2894501C (en) 2012-12-11 2020-01-14 Rockwool International A/S A method of forming a cured mineral fibre product

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RU2694377C2 (en) 2019-07-12
EP3224395A1 (en) 2017-10-04
PL3224395T3 (en) 2019-04-30
RU2017120969A3 (en) 2019-05-24
US10214840B2 (en) 2019-02-26
RU2017120969A (en) 2018-12-26
SI3224395T1 (en) 2019-07-31
WO2016083368A1 (en) 2016-06-02
US20170321359A1 (en) 2017-11-09

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